Wire take-up apparatus



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Oct. 29, 1968 L P. HAUCK ET AL 3,408,013

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IRE TAKE-UP APPARATUS 4 Sheets-Sheet Filed March 29, 1967 Oct. 29, 1968 1 p, HAUCK ET AL 3,408,013

WIRE TAKE-UP APPARATUS" Filed March 29. 1967 4 Sheets-Sheet 4 United States Patent O 3,408,013 WIRE TAKE-UP APPARATUS Leon P. Hauck, Tonawanda, and Horst L. Woellner,

Colden, N.Y., assignors to Western Electric Company, Incorporated, New York, NX., a corporation of New York Filed Mar. 29, 1967, Ser. No. 626,896 15 Claims. (Cl. 242-25) ABSTRACT OF THE DISCLOSURE In an apparatus for continuously taking up wire, a wire is automatically tr-ansferred from a full take-up reel to an adjacent empty take-up reel during as snagging operation. Normally, a wire distributor is moved back and forth a full stroke in a path between spaced planes extending normal to the reel axis adjacent the reel flanges to uniformly distribute the wire in layers on the reel on which the Wire is being wound. The distributor stroke is shortened just before the reel is full whereby the wire is confined by the distributor to a single fixed shorter path near the inside reel flange to facilitate the transfer of the wire to the adjacent empty reel.

BACKGROUND OF THE INVENTION (1) Field of the invention-The invention is concerned with the manufacture of wire. More particularly, the invention is concerned with taking up wire continuously after a processing operation such as the extrusion of insulation on a wire wherein the wire is transferred from a full take-up reel to an adjacent empty take-up reel.

(2) Description of the prior art.-As disclosed in Jacobs et al. Patent 2,971,707, it is advantageous in transferring a wire from a full take-up reel to an empty takeup reel, wherein toothed snagger plates are mounted face to face with each other on the respective reels, to use a curved guide or fender to keep the wire clear of the teeth until the wire reaches a desirable snagging position in a quadrant at the lower half of the reels. The wire is snagged first by a tooth of the snagger plate of the full reel and then by a tooth of the snagger plate of the empty reel whereupon the wire is drawn across a knife as the winding commences on the empty reel. Ordinarily, the wire is traversed back and forth by the distributor between a pair of limit switches which function to reverse the direction of the distributor as the wire is wound uniformly in layers on the take-up reel.

When a transfer is to be made, the distributor shifts L from its immediate position overlying the full reel to a corresponding position overlying the empty reel. It is during the transfer that the snagging and cutting of the wire takes place. It has been found that the most favorable position for transfer is when the wire is close to the inside y flange of the full reel since in that position the wire has no difficulty in clearing the previously mentioned fender. The most unfavorable position for transfer is when the wire is adjacent the outside flange of the full reel. It has been determined that in some cases with the wire in the latter position, the snagger of the empty reel does not snag the wire soon enough and the wire is dragged past the knife by the full reel snagger and severed without a transfer taking place.

One proposed apparatus for assuring that a wire will be in a favorable position for transfer is disclosed in Hauer Patent 2,971,711. In that patent when a take-up reel is almost full the distributor remains in a fixed position adjacent the inside flange and the last turns tend to pile up at that position. The arrangement of that patent for accomplishing the favorable position of transfer is somewhat involved. Further, it is preferable that no pile up ICC occurs adjacent the flange since a pile up of wire could cause tangling of the wires 4and wire breakage particularly when wires of fine gauge are being processed. The Hauer patent does not disclose a curved guide and the main object in providing a favorable wire transfer position is to minimize tension variation on the wire.

SUMMARY OF THE INVENTION In order to overcome the problems discussed is proposed to provide an additional limit switch intermediate each pair of limit switches which control the reciprocation of the distributor by operation of a pair of solenoids as the wire is being wound in layers on a take-up reel. At a predetermined time, when the reel is almost full, the additional limit switch is placed in a parallel circuit with the outer limit switch. Thus, if at this predetermined time the distribution point is between the intermediate limit switch and the inside limit switch the distributor will be reversed when it encounters the intermediate limit switch. The timing is arranged such that if the distribution point at the predetermined time is beyond the intermediate limit switch the distributor moves to the outside limit switch, is returned in the opposite direction, and thereafter is confined to the region betwen the intermediate limit switch and the inside limit switch. In summary, the stroke of the distributor has been shortened to 'a path lying towards the inside flange of the reel. Preferably, the intermediate switch is placed close to the inside limit switch. The reel take-up speed and timing of the distributor is such that just enough wire remains to be wound on the reel after the intermediate switch has been cut in to assure that the wire may move from the intermediate switch if Iat that position to the outside limit switch and back beyond the intermediate limit switch. It has been found that when transfer is made from a point near the inside flange that transfer failures are substantially eliminated. Obviously, the invention is not limited to take-up apparatus using a fender or to wire since it may conceivably be used for winding other continuous elongated articles, strand material generally, for wire pairs, and even for small size cables. Further, the invention may be used to control the final position of a wire on a single take-up reel.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is ya schematic diagram of a wire take-up apparatus;

FIG. 2 is a schematic diagram showing a wire in its most unfavorable position for transfer;

FIG. 3 is a schematic diagram showing a wire in its most favorable position for transfer;

FIG. 4 is a schematic diagram, particularly illustrating the lsnagging of the wire by the empty supply reel snagger plate;

FIG. 5 is a schematic :diagram of the new distributor control;

FIG. 6 is a drawing showing the distributor carriage driving system;

FIG. 7 is a schematic drawing of the electrical control circuit for the distributor control; and

FIG. 8 is a pictorial illustration of a portion of the control circuit.

DETAILED DESCRIPTION In FIG. l, a wire 10 is shown `drawn by a capstan unit 11, which includes a tach generator 9, from an extruder apparatus 12 after which the wire proceeds about an accumulator 13 comprising a pair of sheave banks 14 and 16 about which the wire is looped. rl`he wire engages a follower sheave 20 which drives a pulse generator 17 for measuring the length of the Wire being fed by sending an impulse to an electronic counter 18 for every two feet of wire. The wire moves about a centrally located sheave 19 to a distributor 21 and then to the particular take-up reel 22 or 23 taking up the wire. The reels are respectively ldriven by motors 24 and 26. A potentiometer 27 coupled to the accumulator 13 regulates the speed of the particular reel 22 or 23 on which the wire is being wound. As is well known, in order to match the constant linear speed of the Wire the take-up speed must Ibe reduced as the :diameter of the winding builds up. The wire is looped back and forth about the sheave banks 14 and 16 in a conventional manner. Upper sheave bank 14 is maintained in a fixed position while lower sheave bank 16 is movable upwardly and downwardly in slideways (not shown) and by means of a chain drive (not shown) controls the potentiometer 27 which in turn may control one or the other eddy current clutches (not shown) associated with motors 24, 26. The position of the lower sheave bank 16 is a measure of the wire tension and the diameter of the supply on the reel taking up the wire. The tach generator 9 of the capstan unit 11 generates a continuous voltage signal to control the eddy current clutch of an empty reel when that reel is brought up to speed on operation of relay R as will be explained.

In FIG. 2, distributor 21 is shown in the most unfavorable position for transfer from the full reel 22 to the empty reel 23. The reel drive shafts 25, 30 have respectively attached thereto the snagger plates 28, 38 having teeth 29. Intermediate the reels is a curve-d guide 31 including an upper guard 32 and a lower narrower guard 33. The upper guard 32 overlies the teeth 29 of the snagger plates 28, 38, while the lower guard 33, which is a continuation of the upper guard, is intermediate the teeth 29 of the respective snagger plates. When a transfer is to be made the distributor is shifted from position A to position B. With the distributor 21 in the B position it has been found that a tooth 29 of the snagger plate 28 snags the wire as it moves downwardly beyond the lower left corner 35 of the upper guard 32. The wire may be carried around by the tooth 29 and brought into engagement with the knife 34. As a consequence, the wire is cut before the wire has a chance to move below the lower right corner 36 of the upper guard 32 for engagement by an oncoming tooth of the snagger plate 38. Thus, the Wire from the distributor 21 dangles and no crossover is made to the empty reel. In this connection, it may be observed that the crossover position of the wire is improved as the distributor moves to the right from position B but this movement is too slow to avoid the crossover failure described.

During a successful snagging operation, as indicated, when transferring from full reel 22 to empty reel 23, the wire is snagged first by the snagger plate 28 and then by the snagger plate 38. The snagger plates carry the wire past knife 34 to sever the wire and the winding of the Wire commences on the empty reel 23. Obviously, the situation reverses if reel 23 were the full reel and reel 22 were the empty reel.

Since the core surface speed at the core 37 of reel 23 must be matched to the linear speed of the wire the empty reel 23, prior to transfer, is brought up from zero speed to the wire linear speed. Since the reel 22 is in the full condition and the diameter of the winding is substantially at the maximum condition, it is being driven at a speed considerably less than the speed of the empty reel. The difference in revolutions per minute between the empty reel and full reel is approximately 2.5 to l. As a consequence, the teeth of snagger plate 38 are moving much faster than the teeth of snagger plate 28. The portion of the wire snagged by a tooth of snagger plate 28 is already beyond the lower guide when a tooth of the snagger plate 38 snags another portion of the wire. Because the snagger tooth of plate 38 holding the wire portion is moving at a much greater speed it moves into substantially the same rotary position as the tooth engaging the other portion of the Wire just prior to engagement with the knife 34. As a result, the section of the wire between the snagged plates is substantially parallel to the reel axes as the wire is severed. While the guide 31 assures that there will be no stretching and breaking of the wire during snagging due to the relative speeds of the snagger plates, or premature engagement with the teeth, it does present a. crossover problem as has been described.

It is apparent from the preceding description that when the distributor is in position A', i.e., the most favorable position, and shifted to position B' as shown in FIG. 3, the wire 10 readily clears the lower right hand corner 36 and does not hang up as previously described in connection with FIG. 2.

Prior to the present invention, one pair of limit switches LSlL, LSZL controlled the wire distributor 21, for one take-up reel, for example, reel 22 and a second pair of limit switches, LSIR, LSZR, controlled the wire distributor 21 for the other take-up reel 23. The limit switches control a pair of solenoids DRS, DLS, FIG. 7, which in turn control a four-way valve (not shown) to operate the piston rod S7 of hydraulic cylinder 56 back and forth. The piston rod 57 drives distributor 21 back and forth along rods 53, 54 as the wire is wound on a supply reel. The piston rod 57 of the hydraulic cylinder 56 is coupled by means of a bracket 58 to plate 59 attached to the movable carriage 61 which supports transfer air cylinder 52 and is mounted on the rods 53, 54. Thus, when a transfer is to be made the air cylinder 52 is operated or unoperated, always a full stroke, to drive the distributor 21, through its piston rod 90, rapidly to the right or left along rods 53, 54 to enable the distributor 21 to distribute the wire on one reel or the other. The front end of piston rod is coupled to distributor 21 as shown in FIG. 7. The distributor, of course, is shifted from the full reel to the empty reel. The distributor includes a cam 60 which operates the limit switches LSIL, LSZL, LSlR, LS2R. The cam 60 additionally controls a centrally located directional control limit switch LSDC. The positions of the limit switches may be adjusted longitudinally along rod 65 as desired. Eye guide 71 and pins 72 assist in guiding the Wire to the reel being wound. As viewed in FIG. 2, when the distributor is in the righthand position overlying reel 22 the axis of eye guide 71 is in a plane extending normal to the reel axis and when the distributor 21 is in the lefthand position the eye guide lies in a similar plane parallel to the other plane.

In accordance with the present invention, in order to maintain the distributor in a favorable position for transfer of the wire from a full reel to an empty reel, intermediate limit switches LSILL and LS2RR have been added. These limit switches are'likewise under the control of cam 60 carried by the distributor 21. When cut in, the intermediate limit switches perform the function of the outside limit switches LS1L and LS2R. It is preferable that the intermediate limit switches are about 1%" from the inside limit switches LS2L and LSIR. This distance could be from the respective center lines of cam engagement. The full core length of a small size reel is 4%" and of a large size reel is /3". Obviously, the position of the intermediate limit switches can be adjusted to meet varying operating conditions, the dimensions mentioned being only by way of example. Directional conductor 70 is operated by the cam 60 on transfer of the distributor 21 from a full reel to an empty reel, as later described.

OPERATION With particular, but not exclusive, reference to FIGS. 7 and 8, the operation of the take-up apparatus will now be described. It will rst be assumed that 28,000 feet of wire is to be wound on a reel with the extrusion line operating at 4500 feet per minute or 75 feet per second. It will be assumed further that the wire is being wound on reel 22 and distributor 21 is moving back and forth between limit switches LS1L and LS2L to lay the wire on the reel in uniform layers. At this time, pulse generator 17 is sending pulses to the counter 18 to measure continuously the wire length. Counter 18 has two preset position controls PSC1, PSC2, one of which is set for 25,750 feet which is the transfer ready condition and the other of which is set for 28,000 feet which is the transfer condition.

Under the assumed condition with cam 60 moving to the left, distribution relay DR in FIG. 7 is energized, solenoid DLS is energized, and contacts DRl and DR3 are closed while contact DR2 is open. When cam 60 reaches normally closed limit switch LSlL the path for distribution relay DR is broken de-energizing that relay to open contacts DR1 and DR3 and close contact DRZ thereby energizing solenoid DRS which operates the hydraulic cylinder S6 to drive the distributor to the right. Cam 60 on returning to the right engages normally open limit switch LS2L re-energizing distributor relay DR and again contacts DR1 and DR?, are closed while contact DR2 is opened. This causes the 4operation of solenoid DLS which operates hydraulic cylinder 56 to drive the distributor to the left. In this manner, the cycle continues.

When the counter has registered 25,750 feet, a first preset counter control closes contact PTR to start the operation of timer ET which is set for 28 seconds and causes the operation of empty reel drive relay R. The latter relay starts the drive of the empty reel 23 which is brought up to the required core surface speed to match the linear speed of the wire which is 4500 feet per minute. Relay R renders the tach generator 9 effective to send a continuous voltage signal to control the eddy current clutch of the empty reel.

After 28 seconds, the timer ET times out and normally open contact ETI closes while normally closed contact ETZ opens. This now places both intermediate limit switches LSlLL and LSZRR in their operating condition although we are only interested in the former at this time.

When cam 60 now reaches intermediate limit switch LSlLL in its travel to the left, that switch is opened and relay DR is de-energized just as it was Ion operation of outside limit switch LS1L.

After the 28 second period has elapsed, the counter will read 27,850 feet and 2 seconds will remain which is the time necessary to take-up the last 150 feet of wire. The 2 second time interval is sufficient for the cam 60 to move from the intermediate switch LSlLL, if at that position, completely to the left, then back to the right beyond intermediate limit switch. Of course, if the cam had been between intermediate limit switch LSILL and inside limit switch LS2L at the end of the 28 second interval it will remain in that region. At the end of the 2 second interval, the second preset counter control closes contact PTC, the transfer solenoid TS is operated and the distributor 21 `is transferred to the empty reel. Even if the distributor remains between the intermediate limit switch LS1LL and inside limit switch LS2L only a relatively small amount of wire remains to be wound and it is uniformly distributed between those switches without pile up.

When the distributor 21 is transfered from a full reel to an empty reel as explained, it is moved so rapidly by air cylinder 52 that it assumes a position overlying the empty reel almost identical to the position it assumed overlying the full reel yat the time of transfer. As the cam 60 engages centrally located directional limit switch LSDC, on transfer, directional control 70 is operated, the counter 18 is reset, the timer ET is reset, and the control of the empty reel by tach `generator 9 is switched to potentiometer 27. The directional control also conditions suitable contacts (not shown) for controlling the operation of transfer solenoid TS. For example, when the transfer solenoid TS -for air cylinder 52 is operated the distributor 21 moves from left to right on operation of contact PTC. The control is such that when the second preset control -PSCZ operates in counter 18 with the distributor in the right position, contact PTC is opened, and the transfer solenoid TS is de-energized to drive the distributor back to the left, overlying the empty reel which replaced the previously wound reel.

The limit switches LSIR, LSZRR and LSZR operate respectively in the same maner as their counterpart limit switches LSlL, LSILL, and LS2L.

If the counter 18 were provided with three preset controls, timer ET could be eliminated and its function performed by a third preset control.

It will be understood that various changes and modifications may be made in the invention as described without departing from the spirit of the invention.

What is claimed is:

1. A take-up apparatus for wire and the like comprismg:

driving means adapted to drive a take-up reel,

a distributor for normally distributing the wire in layers between spaced planes extending normal to the axis of the reel on which the wire is being wound,

means for driving the distributor back and forth to distribute the wire in a path lying between said planes, and

means for altering the operation of the distributor driving means to confine the back and forth motion of the distributor to a single lixed path substantially less in length than the path between the spaced planes.

2. A take-up apparatus, according to claim 1, comprising:

an electrical control circuit for reversing the stroke of the distributor driving means inculding:

a limit switch at each of the spaced planes between which the distributor normally operates, and

the altering means which comprises a limit switch intermediate the spaced planes,

counting means for measuring the length of a wire being wound,

the electrical control circuit including means responsive to a signal from the counting means when a predetermined length of wire has been measured to render the intermediate limit switch effective to confine the distribution of the wire by the distributor to a path between one of the limit switches at the spaced planes and the plane of the intermediate limit switch as the tinal portion of the wire is being wound on the reel.

3. A take-up apparatus for wire and the like comprising:

driving means adapted to drive a pair of take-up reels positioned adjacent each other.

a distributor for normally distributing the wire in layers between spaced planes extending normal to the axis of the reel on which the wire is being Wound,

means `for driving the distributor back and forth to ldistribute the wire in a path lying between said spaced planes,

means for transferring the distributor from a reel after a full supply is wound thereon to an adjacent empty reel, and

means for confining the back and forth motion of the distributor to a single fixed path lying between one of said planes and a parallel plane intermediate said plane just prior to a reel reaching its fully wound condition.

4. A take-up apparatus, according to claim 3, comprising:

a snagger means for each reel adjacent the inside flange of each reel, and

a curved guide between the reels,

the spaced planes being respectively adjacent the outside and inside flanges of a reel, and the intermediate 7 plane lying closer to the inside flange than to the outside flange of a reel,

the intermediate plane being selected to assure that the wire clears the guide and each snagger means snags the wire when the wire is transferred to the empty reel.

5. A take-up apparatus, according to claim 4, wherein:

the curved guide includes a tirst portion whose edges extend beyond the teeth of each snagger means, and

a reduced second portion below the first portion and intermediate the two snagger means.

6. A take-up apparatus, according to claim 4, comprising:

a knife intermediate the two snagger means for severing the wire after being snagged.

7. A take-up apparatus, according to claim 3, comprising:

an electrical control circuit for reversing the stroke of the distributor including:

a limit switch at each of the spaced planes for each reel, and

the contining means which comprises a limit switch at each intermediate plane,

cam means on the distributor for engaging the limit switches during the movement of the distributor, the limit switches at the spaced planes normally being effective to reverse the distributor when engaged by the cam means, and

counting means for measuring the length of the wire,

the control circuit including means responsive to a signal from the counting means when a reel is approaching the full condition -for rendering the intermediate limit switch effective to reverse the motion of the distributor when engaged by the cam means.

8. A take-up apparatus, according to claim 7, wherein the control circuit includes:

timing means rendered effective on receipt of the signal from the counter, to initiate a time count determinative of when the intermediate switch is to be made eective,

means responsive to the operation of the timing means at the end of the count for rendering the intermediate switch effective, and

means responsive to a signal received thereafter from the counter for electing the operation of the transfer means.

9. A take-up apparatus, according to claim 8, comprising:

a limit switch centrally located between the reels and oper-able by the cam means on operation of the transfer means for returning the control circuit to its normal condition, and for resetting the counter and the timer.

10. A take-up apparatus, -according to claim 8, cornprising:

means responsive to the receipt of a signal from the counting means for bringing the empty reel up to speed prior to transfer of the wire.

11. A take-up apparatus, according to claim 3 wherein:

the spaced planes lie adjacent the flanges of the reel,

the one plane lies adjacent the inside flange, and

the `distance between the intermediate plane and the one plane is less than one-half the distance between the spaced planes.

12. A take-up apparatus, according to claim 3, wherein:

the driving means for the distributor includes a fluidoperated cylinder and piston.

13. A take-up apparatus, according to claim 3, wherein:

the transferring means comprises a fluid-operated cylinder and piston.

14. A take-up apparatus, according to claim 1, comprism g an electrical control circuit for reversing the operation of the distributor driving means including:

a pair of limit switches spaced apart a distance corresponding to the distance between the spaced planes, and

the altering means which comprises a limit switch intermediate the spaced limit switches,

means for measuring the length of the wire being wound, and

the electrical control circuit including means responsive to a signal from the counting means when a predetermined length of wire has been measured to render the intermediate limit switch eiective to conline the back and forth distribution of the wire by the distributor to the single lixed path as the final portion of the wire is being wound on the reel.

15. A take-up apparatus according to claim 3, comprising:

an electrical control circuit for reversing the stroke of the distributor including:

a pair of limit switches for each reel, the limit switches of each pair being spaced apart a distance corresponding to the distance between the spaced planes, and

the confining means which comprises a limit switch intermediate the spaced limit switches of each pair,

means for measuring the length of the wire being wound, and

the electrical control circuit including means responsive to a signal from the counting means when a predetermined length of wire has been measured to render an intermediate limit switch effective to conne the back and forth distribution of the wire by the distributor to a path corresponding to the distance between the intermediate limit switch and one of the limit switches of -a pair.

References Cited UNITED STATES PATENTS FRANK J. COHEN, Primary Examiner.

N. L. MINTZ, Assistant Examiner. 

